Footwear Article and Knitted Shoe Upper and Manufacturing Method Thereof

ABSTRACT

A footwear article includes a sole and a knitted shoe upper secured to the sole. The knitted shoe upper includes a knitted fabric including a plurality of portions knitted from at least one yarn and a plurality of inlaid strands. The plurality of portions include a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion together to enclose a three-dimensional space for receiving a foot. The plurality of inlaid strands are inlaid in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The invention generally relates to a footwear article and a knitted shoe upper and a manufacturing method thereof. Particularly, the invention relates to a footwear article and a knitted shoe upper and a manufacturing method thereof, which restricts relative displacements toward different directions.

2. Description of the Prior Art

Conventional shoes made of leathers or polymers are generally poor in ventilation due to the materials used and may sometime even cause uncomfortable feeling. In the conventional shoe-making process, a large amount of materials will be wasted during the cutting, jointing, trimming processes likely to cause environmental issues and also increase the manufacturing cost. Therefore, owing to better stretchability and softness, knitted shoes have quickly developed and gradually occupied a place in the market.

However, in intense sports, such as basketball and soccer games, the actions of suddenly running, stopping, and jumping frequently occur, so the sports shoes made of knitted upper tend to cause undesired displacements of shoe upper due to its high stretchability and softness, likely to cause injury of the wearer.

SUMMARY OF THE INVENTION

In view of the prior arts, it is an object of the present invention to provide a knitted shoe upper and a manufacturing method thereof, which has inlaid strands arranged in predetermined portions of the knitted fabric to improve the local structural strength and form the support structure of the shoe upper.

It is another object of the invention to provide a footwear article, which includes the knitted shoe upper described above, to restrict relative displacements at different directions by the inlaid strands disposed along different directions around the knitted fabric, so as to effectively reduce the possibility of injury of the wearer.

In an embodiment, the knitted shoe upper of the invention includes a knitted fabric and a plurality of inlaid strands. The knitted fabric includes a plurality of portions formed by knitting at least one yarn. The plurality of portions includes a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion together to enclose a three-dimensional space for receiving a foot. The plurality of inlaid strands are inlaid in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion.

In an embodiment, the plurality of inlaid strands includes a first inlaid strand extending along the inner lateral portion around the front portion to the outer lateral portion, a second inlaid strand extending along the inner lateral portion around the heel portion to the outer lateral portion, and a third inlaid strand extending along the inner lateral portion around the instep portion to the outer lateral portion.

In an embodiment, the first inlaid strand, the second inlaid strand, and the third inlaid strand start from adjacent locations of the inner lateral portion and end at adjacent locations of the outer lateral portion.

In an embodiment, the plurality of portions further include a sole portion. The first inlaid strand, the second inlaid strand, and the third inlaid strand further extend to the sole portion from the inner lateral portion and the outer lateral portion.

In an embodiment, the first inlaid strand, the second inlaid strand, and the third inlaid strand start from and end at a middle portion of the sole portion, and the middle portion substantially corresponds to an arch portion of the foot.

In an embodiment, the first inlaid strand, the second inlaid strand, and the third inlaid strand are different sections of a single inlaid strand.

In an embodiment, the knitted fabric has an inner surface and an outer surface. The plurality of portions include a plurality of stitches formed by the at least one yarn. The plurality of inlaid strands extend through the plurality of stitches to be in and out of the inner surface and the outer surface.

In another embodiment, the invention provides a footwear article including a sole and the knitted shoe upper described above and secured to the sole.

In another embodiment, the invention provides a method of manufacturing a knitted shoe upper including: forming a knitted fabric by knitting at least one yarn, the knitted fabric having a plurality of portions including a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion to enclose a three-dimensional space for receiving a foot, and inlaying a plurality of inlaid strands in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion.

In an embodiment, the step of inlaying the plurality of inlaid strands is performed during formation of the knitted fabric.

In an embodiment, the step of inlaying the plurality of inlaid strands includes: inlaying a first inlaid strand, so the first inlaid strand extends along the inner lateral portion around the front portion to the outer lateral portion; inlaying a second inlaid strand, so the second inlaid strand extends along the inner lateral portion around the heel portion to the outer lateral portion; and inlaying a third inlaid strand, so the third inlaid strand extends along the inner lateral portion around the instep portion to the outer lateral portion.

In an embodiment, the step of inlaying the plurality of inlaid strands includes enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to start from adjacent locations of the inner lateral portion and end at adjacent locations of the outer lateral portion.

In an embodiment, the step of forming the knitted fabric further includes forming a sole portion, and the step of inlaying the plurality of inlaid strands further includes enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to further extend to the sole portion from the inner lateral portion and the outer lateral portion.

In an embodiment, the step of inlaying the plurality of inlaid strands includes enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to start from and end at a middle portion of the sole portion, and the middle portion substantially corresponds to an arch portion of the foot.

In an embodiment, the step of inlaying the plurality of inlaid strands includes inlaying a single inlaid strand in the knitted fabric to form the first inlaid strand, the second inlaid strand, and the third inlaid strand.

In an embodiment, the knitted fabric has an inner surface and an outer surface. The plurality of portions include a plurality of stitches formed by the at least one yarn. The step of inlaying the plurality of inlaid strands includes enabling the plurality of inlaid strands to extend through the plurality of stitches to be in and out of the inner surface and the outer surface.

Compared with the prior art, the footwear article and the knitted shoe upper and the manufacturing method thereof of the invention not only maintain the characteristic of good ventilation and high stretchability of the knitted fabric to improve the wearing comfort, but also improve the shoe support structure by the inlaid strands to restrict relative displacements at different directions and effectively reduce the possibility of injury of the wearer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a footwear article in an embodiment of the invention.

FIG. 2 is a schematic view of a knitted fabric in an embodiment of the invention.

FIG. 3 is a schematic view of a knitted fabric in another embodiment of the invention.

FIGS. 4A and 4B are a schematic view and a cross-sectional view of the inlaid strands in the knitted fabric in an embodiment of the invention, respectively.

FIG. 5 is a flowchart of a method of manufacturing a knitted shoe upper in an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown FIG. 1, the footwear article 10 of the invention includes a knitted shoe upper 100 and a sole 200. The knitted shoe upper 100 is secured to the sole 200. The knitted shoe upper 100 includes a knitted fabric 110 and a plurality of inlaid strands (e.g. 122, 124, 126). The knitted fabric 100 includes a plurality of portions formed by knitting at least one yarn. The plurality of portions include a front portion 111, an instep portion 112, an inner lateral portion 113, an outer lateral portion 114, and a heel portion 115 together to enclose a three-dimensional space 10 a for receiving a foot. The plurality of inlaid strands are inlaid in the knitted fabric 110 along different directions of the three-dimensional space 10 a, so as to restrict relative displacements of the knitted fabric 110 toward the front portion 111, the heel portion 115, and the instep portion 112.

Specifically, the sole 200 can be any suitable sole and include functional elements for providing cushion and support. For example, according to practical applications, the sole 200 may include an outsole, a midsole, and an insole. The knitted shoe upper 100 can be secured to any appropriate locations of the sole 200 by any suitable securing techniques, such as seaming, adhering, bonding. The knitted shoe upper 100 may be a three-dimensional shoe upper formed by shaping a two-dimensional knitted fabric 110 having a plurality of courses and wales formed by knitting at least one yarn (shown in FIG. 2) or a three-dimensional knitted fabric 110′ having a plurality of courses and wales formed by knitting at least one yarn (shown in FIG. 3). The course is defined as a horizontal row of stitches, while the wale is defined as a vertical column of intermeshed stitches. In other words, the course is a meandering path along which the yarn is knitted and the extending direction of the wale crosses the extending direction of the course. It is noted that the number, color, material, and knitting method of the yarn of the knitted fabric 110/110′ can be determined according to the requirements of stretchability, color, pattern for different portions. In addition, the knitted fabric 110/110′ may have a single-layer or multiple-layer structure and have different pattern designs for different applications of shoes.

Ash shown in FIG. 2, in an embodiment, for the knitted shoe upper formed by the two-dimensional knitted fabric 110, the portion of the knitted fabric 110 corresponding to the sole is an opening. The front portion 111, the instep portion 112, the inner lateral portion 113, the outer lateral portion 114, and the heel portion 115 are connected (such as seamed) to enclose the three-dimensional space 10 a for receiving the foot. The front portion 111 generally corresponds to the toes of the foot. The instep portion 112 generally corresponds to the instep of the foot. The inner lateral portion 113 and the outer lateral portion 114 generally correspond to two lateral sides of the foot, respectively. For example, the inner lateral portion 113 corresponds to an inside lateral area of the foot, i.e. the surface that faces toward the other foot. The outer lateral portion 114 corresponds to an outside area of the foot, i.e. the surface that faces away from the other foot. The heel portion 115 generally corresponds to the rear portion of the foot including the calcaneus bone. It is noted that the division of the plurality of portions of the knitted fabric is provided for explanation, and thus the knitted fabric can be divided into different ways.

The plurality of inlaid strands include a first inlaid strand 122, a second inlaid strand 124, and a third inlaid strand 126. The first inlaid strand 122 extends along the inner lateral portion 113 around the front portion 111 to the outer lateral portion 114, so as to restrict the relative displacement of the knitted fabric 110 toward the front portion 111. In other words, by inlaying the first inlaid strand 122 from one side of the knitted fabric 110 (e.g. the lateral portion 113) to the front portion 111, and extending around the front portion 111 to the other side of the knitted fabric 110 (e.g. the outer lateral portion 114), a reinforced structure toward the forward direction can be formed, and the relative displacements of the footwear article 10 toward the front side and the lateral sides can be restricted. The second inlaid strand 124 extends along the inner lateral portion 113 around the heel portion 115 to the outer lateral portion 114, so as to restrict the relative displacement of the knitted fabric 110 toward the heel portion 115. In other words, by inlaying the second inlaid strand 124 from one side of the knitted fabric 110 (e.g. the lateral portion 113) to the heel portion 115, and extending around the heel portion 115 to the other side of the knitted fabric 110 (e.g. the outer lateral portion 114), a reinforced structure toward the rearward direction can be formed, and the relative displacements of the footwear article 10 toward the rear side and the lateral sides can be restricted. The third inlaid strand 126 extends along the inner lateral portion 113 around the instep portion 112 to the outer lateral portion 114, so as to restrict the relative displacement of the knitted fabric 110 toward the instep portion 112. In other words, by inlaying the third inlaid strand 126 from one side of the knitted fabric 110 (e.g. the lateral portion 113) to the instep portion 112, and extending around the instep portion 112 to the other side of the knitted fabric 110 (e.g. the outer lateral portion 114), a reinforced structure toward the upward direction can be formed, and the relative displacements of the footwear article 10 toward the up side and the lateral sides can be restricted.

In an embodiment, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 preferably start from adjacent locations of the inner lateral portion 113 and end at adjacent locations of the outer lateral portion 114. In other words, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 preferably start and end at close locations on two opposite sides, so the plurality of inlaid strands 122, 124, and 126 are considered as extending from a substantially same location toward different directions to have a structure similar to the suspension bridge. Therefore, the plurality of inlaid strands 122, 124, and 126 form a support structure for the knitted shoe upper 100, to enhance the structural strength at multiple directions and reduce the occurrence of overstretch.

In another embodiment, as shown in FIG. 3, for the knitted shoe upper formed by the three-dimensional knitted fabric 110′, the plurality of portions of the knitted fabric 110′ further include a sole portion 116, which corresponds to the plantar area of the foot. In this embodiment, after the knitting process of the front portion 111, the instep portion 112, the inner lateral portion 113, the outer lateral portion 114, the heel portion 115, and the sole portion 116 of the knitted fabric 110′ is completed, the three-dimensional space 10 a is formed without additional seaming process.

As shown in FIG. 3, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 further extend to the sole portion 116 from the inner lateral portion 113 and the outer lateral portion 114. Specifically, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 preferably start from and end at a middle portion of the sole portion 116, and the middle portion substantially corresponds to an arch portion of the foot. In embodiment, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 can be three independent inlaid strands, but not limited thereto. In another embodiment, the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 can be different sections of a single inlaid strand. In other words, the single continuous inlaid strand can start from the middle portion of the sole portion 116 and extend toward one side of the knitted shoe upper 100 (e.g. the inner lateral portion 113) and then to the front portion 111, further extend around the front portion 111 to the other side of the knitted shoe upper 100 (e.g. the outer lateral portion 114) and back to the middle portion of the sole portion 116, so as to form the first inlaid strand 122. Then, the single continuous inlaid strand continues extending from the middle portion of the sole portion 116 and extends toward one side of the knitted shoe upper 100 (e.g. the inner lateral portion 113) and then to the heel portion 115, further extends around the heel portion 115 to the other side of the knitted shoe upper 100 (e.g. the outer lateral portion 114) and back to the middle portion of the sole portion 116, so as to form the second inlaid strand 124. The single continuous inlaid strand again continues extending from the middle portion of the sole portion 116 and extends toward one side of the knitted shoe upper 100 (e.g. the inner lateral portion 113) and then to the instep portion 112, further extends around the instep portion 112 to the other side of the knitted shoe upper 100 (e.g. the outer lateral portion 114) and back to the middle portion of the sole portion 116, so as to form the third inlaid strand 126. It is noted that the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 can be formed by the single inlaid strand in a different order, not limited to the embodiment. Moreover, the inlaid strand 122/124/126 can start from any suitable location, not limited to the inner lateral portion 113 or the sole portion 116. In other embodiments, according to the knitting process, the inlaid strand 122/124/126 can start from the front portion 111 or the heel portion 115 toward the two lateral portions 113 and 114.

As shown in FIGS. 4A and 4B, in an embodiment, the plurality of inlaid strands (such as the first inlaid strand 122 shown in the drawings) can extend through the plurality of stitches of the courses of the knitted fabric 110/110′ to be in and out of the inner surface 100 a and the outer surface 100 b, but not limited thereto. The plurality of inlaid strands (such as 122, 124, and 126) can extend through the plurality of stitches of the wales and/or courses of the knitted fabric 110/110′ along predetermined paths to be in and out of the inner surface 100 a and the outer surface 100 b.

Furthermore, in an embodiment, the inlaid strands 122, 124, and 126 can be formed by yarns, but not limited thereto. In another embodiment, the inlaid strands 122, 124, and 126 may have the configurations of a filament (e.g., a monofilament), thread, rope, webbing, cable, or chain, for example. The materials forming the inlaid strands 122, 124, and 126 may include any suitable materials such as cotton, elastane, polyester, rayon, wool, and nylon. In addition, three inlaid stands 122, 124, and 126 are illustrated in the embodiment, but not limited thereto. In another embodiment, the first inlaid strand 122 and the second inlaid strand 124 can be integrated as a circular inlaid strand, which extends from the front portion 111 to the heel portion 115 through the inner lateral portion 113 and the outer lateral portion 114, so as to restrict the forward and rearward displacements. Furthermore, one inlaid strand is illustrated to represent the enhanced structure toward one direction, but not limited thereto. In another embodiment, multiple inlaid strands can be inlaid toward the same direction or an inlaid strand of higher strength can be inlaid at a region required higher structural strength and supportability.

In another embodiment, as shown in the flowchart of FIG. 5, the invention provides a method of manufacturing a knitted shoe upper including the following steps.

At step 510, the step includes forming a knitted fabric by knitting at least one yarn. The knitted fabric includes a plurality of portions. The plurality of portions includes a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion together to enclose a three-dimensional space for receiving a foot. Specifically, at the step 510, the knitted fabric 110 of FIG. 2 or the knitted fabric 110′ of FIG. 3 can be formed. The knitted fabric 110/110′ includes a plurality of portions, such as the front portion 111, the instep portion 112, the inner lateral portion 113, the outer lateral portion 114, and the heel portion 115, to enclose the three-dimensional space 10 a.

At step 520, the step includes inlaying a plurality of inlaid strands in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion. Specifically, as shown in FIG. 2, the step 520 of inlaying the plurality of inlaid strands includes: inlaying a first inlaid strand 122, so the first inlaid strand 122 extends along the inner lateral portion 113 around the front portion 111 to the outer lateral portion 114, inlaying a second inlaid strand 124, so the second inlaid strand 124 extends along the inner lateral portion 113 around the heel portion 115 to the outer lateral portion 114, and inlaying a third inlaid strand 126, so the third inlaid strand 126 extends along the inner lateral portion 113 around the instep portion 112 to the outer lateral portion 114. Furthermore, the step 520 of inlaying the plurality of inlaid strands further includes enabling the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 to start from adjacent locations of the inner lateral portion 113 and end at adjacent locations of the outer lateral portion 114.

In addition, referring to FIG. 3, the step 510 of forming the knitted fabric further includes forming a sole portion 116, and the step 520 of inlaying the plurality of inlaid strands further includes enabling the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 to further extend to the sole portion 116 from the inner lateral portion 113 and the outer lateral portion 114. The step 520 of inlaying the plurality of inlaid strands may include enabling the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126 to start from and end at a middle portion of the sole portion 116, and the middle portion substantially corresponds to an arch portion of the foot.

In an embodiment, the step 520 of inlaying the plurality of inlaid strands includes inlaying a single inlaid strand in the knitted fabric 110/110′ to form the first inlaid strand 122, the second inlaid strand 124, and the third inlaid strand 126. In addition, the step 520 of inlaying the plurality of inlaid strands includes enabling the plurality of inlaid strands, such as 122, 124, 126, to extend through the plurality of stitches to be in and out of the inner surface and the outer surface of the knitted fabric 110/110′.

It is noted that in the step 510 of forming the knitted fabric 110/110′, the step 520 of inlaying the plurality of inlaid strands i122, 124, and 126 are preferably performed simultaneously during formation of the knitted fabric. In other words, the inlaid strands 122, 124, and 126 are preferably inlaid according to predetermined paths during the formation of the knitted fabric 110/110′ to save the manufacturing cost, but not limited thereto. In another embodiment, the step 520 of inlaying the plurality of inlaid strands 122, 124, and 126 can be performed after the step 510 of forming the knitted fabric 110/110′ is completed.

Although the preferred embodiments of the present invention have been described herein, the above description is merely illustrative. The preferred embodiments disclosed will not limit the scope of the present invention. The invention is susceptible to modifications in many forms, structures, arrangements, proportions, materials, elements, and components. Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention as defined by the appended claims. 

What is claimed is:
 1. A knitted shoe upper, comprising: a knitted fabric comprising a plurality of portions formed by knitting at least one yarn, the plurality of portions comprising a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion to enclose a three-dimensional space for receiving a foot; and a plurality of inlaid strands inlaid in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion.
 2. The knitted shoe upper of claim 1, wherein the plurality of inlaid strands comprise a first inlaid strand extending along the inner lateral portion around the front portion to the outer lateral portion, a second inlaid strand extending along the inner lateral portion around the heel portion to the outer lateral portion, and a third inlaid strand extending along the inner lateral portion around the instep portion to the outer lateral portion.
 3. The knitted shoe upper of claim 2, wherein the first inlaid strand, the second inlaid strand, and the third inlaid strand start from adjacent locations of the inner lateral portion and end at adjacent locations of the outer lateral portion.
 4. The knitted shoe upper of claim 2, wherein the plurality of portions further comprise a sole portion; the first inlaid strand, the second inlaid strand, and the third inlaid strand further extend to the sole portion from the inner lateral portion and the outer lateral portion.
 5. The knitted shoe upper of claim 4, wherein the first inlaid strand, the second inlaid strand, and the third inlaid strand start from and end at a middle portion of the sole portion, and the middle portion substantially corresponds to an arch portion of the foot.
 6. The knitted shoe upper of claim 5, wherein the first inlaid strand, the second inlaid strand, and the third inlaid strand are different sections of a single inlaid strand.
 7. The knitted shoe upper of claim 1, wherein the knitted fabric has an inner surface and an outer surface; the plurality of portions comprise a plurality of stitches formed by the at least one yarn; the plurality of inlaid strands extend through the plurality of stitches to be in and out of the inner surface and the outer surface.
 8. A footwear article, comprising: a sole; and the knitted shoe upper of claim 1, wherein the knitted shoe upper is secured to the sole.
 9. A method of manufacturing a knitted shoe upper, comprising: forming a knitted fabric by knitting at least one yarn, the knitted fabric comprising a plurality of portions comprising a front portion, an instep portion, an inner lateral portion, an outer lateral portion, and a heel portion to enclose a three-dimensional space for receiving a foot; and inlaying a plurality of inlaid strands in the knitted fabric along different directions of the three-dimensional space, so as to restrict relative displacements of the knitted fabric toward the front portion, the heel portion, and the instep portion.
 10. The method of claim 9, wherein the step of inlaying the plurality of inlaid strands is performed during formation of the knitted fabric.
 11. The method of claim 9, wherein the step of inlaying the plurality of inlaid strands comprises: inlaying a first inlaid strand, so the first inlaid strand extends along the inner lateral portion around the front portion to the outer lateral portion; inlaying a second inlaid strand, so the second inlaid strand extends along the inner lateral portion around the heel portion to the outer lateral portion; and inlaying a third inlaid strand, so the third inlaid strand extends along the inner lateral portion around the instep portion to the outer lateral portion.
 12. The method of claim 11, wherein the step of inlaying the plurality of inlaid strands comprises enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to start from adjacent locations of the inner lateral portion and end at adjacent locations of the outer lateral portion.
 13. The method of claim 11, wherein the step of forming the knitted fabric further comprises forming a sole portion, and the step of inlaying the plurality of inlaid strands further comprises enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to further extend to the sole portion from the inner lateral portion and the outer lateral portion.
 14. The method of claim 13, wherein the step of inlaying the plurality of inlaid strands comprises enabling the first inlaid strand, the second inlaid strand, and the third inlaid strand to start from and end at a middle portion of the sole portion, and the middle portion substantially corresponds to an arch portion of the foot.
 15. The method of claim 14, wherein the step of inlaying the plurality of inlaid strands comprises inlaying a single inlaid strand in the knitted fabric to form the first inlaid strand, the second inlaid strand, and the third inlaid strand.
 16. The method of claim 9, wherein the knitted fabric has an inner surface and an outer surface; the plurality of portions comprise a plurality of stitches formed by the at least one yarn; the step of inlaying the plurality of inlaid strands comprises enabling the plurality of inlaid strands to extend through the plurality of stitches to be in and out of the inner surface and the outer surface. 